Method to straighten metallic filament

ABSTRACT

In various exemplary embodiments, the technology described herein provides systems and methods for drawn wire, commonly called filament, to be straightened after cold, warm or hot drawing to a smaller diameter. This technology controls tension on the wire after drawing, while pulling the wire through straightening rollers. A single set of straightening rollers can be used. There is no limit on the total number of sets of straightening rollers can be used. The number of individual rollers in a set of straightening rollers can range from two-to-many rolls. Tension is generally controlled by at least two relatively large diameter synchronizing sets of pulling rollers, one before the straightening rollers and one after the straightening rollers.

FIELD OF THE INVENTION

The technology described herein relates generally to the physicaltreatment of metal products such as drawn wire in steel wiremanufacturing and cord engineering. More specifically, this technologyrelates to systems and methods for straightening metallic filament afterdrawing in producing a steel cord for radial tires or monofilament fortire or other reinforcement applications or other wire applications likemusic wire.

BACKGROUND OF THE INVENTION

For many applications, filament should be straightened before anysubsequent operation is applied. For example, in the manufacture ofsteel tire cord, utilizing a straightened filament prior to twistingwill result in higher fatigue life of the final product. In otherapplications, straightened wire is required to follow a prescribed pathin a subsequent operation. By way of example, when cut filament isautomatically guided into a small hole after cutting, filament with aresidual bend after drawing can result in the filament missing the hole.

Some wire manufacturers utilize slow filament drawing with in-linelarge-diameter pulling rollers to help straighten filament. Thetechnology described herein can be used in line with a high speeddrawing process or off line after drawing.

BRIEF SUMMARY OF THE INVENTION

In various exemplary embodiments, the technology described hereinprovides systems and methods for drawn wire, commonly called filament,to be straightened after wet, cold, warm or hot drawing to a smallerdiameter. This technology controls tension on the wire after drawing,while pulling the wire through straightening rollers. A single set ofstraightening rollers can be used. There is no limit on the total numberof sets of straightening rollers can be used. The number of individualrollers in a set of straightening rollers can range from two-to-manyrolls. Tension is generally controlled by at least two relatively largediameter synchronizing sets of pulling rollers, one before thestraightening rollers and one after the straightening rollers as well asa device to measure and control tension. The filament tension must bevery low during straightening. The tension measuring device (a straingauge, for example) is used to send a signal to the synchronized pullcapstans to maintain the low tension by changing the speed of one pullroller.

In one exemplary embodiment, the technology described herein provides asystem for straightening metallic filament. The system includes: a firstpulling roller; a second pulling roller, the first pulling roller andthe second pulling roller being synchronized to rotate at a synchronizedpace to pull a filament through the system at a predetermined rate; andat least one set of straightening rollers comprising at least tworollers opposed to one another on opposite sides of the filament fromone another. The at least one set of straightening rollers is configuredto straighten the filament prior to a subsequent operation on thefilament.

The first pulling roller can be located prior to the at least one set ofstraightening rollers and the second pulling roller can be locatedsubsequent to the at least one set of straightening rollers.

The filament can be straightened in line with a drawing operation.Alternatively, the filament can be straightened offline during anoperation separate from a drawing process.

The at least one set of straightening rollers can include a first set ofstraightening rollers and a second set of straightening rollers.Alternatively, the at least one set of straightening rollers can includea first set of straightening rollers, a second set of straighteningrollers, and a third set of straightening rollers. There is notheoretical limit to the number of sets of straightening rollersutilized.

The first pulling roller and the second pulling roller are configured tocreate a tension in the filament. The tension can be controlled to be alow value while using the at least one set of straightening rollers torelive a residual stress on the filament that causes the filament tobend.

A diameter of each of the first pulling roller and the second pullingroller is much larger than a diameter of the filament. A diameter of theat least one set of straightening rollers is much smaller than the sizeof the pulling rollers and much closer to a size of the filament.

The system for straightening metallic filament can also include atension measuring device configured to measure a tension on the filamentpulled through the system for straightening metallic filament. Thetension measuring device sends a signal to the synchronized pullingrollers to maintain a very low tension on the filament. If the tensionbecomes too high, the wire will not be straightened.

In yet another exemplary embodiment, the technology described hereinprovides a method for straightening metallic filament. The methodincludes: utilizing a first pulling roller; utilizing a second pullingroller; synchronizing the first pulling roller and the second pullingroller to rotate at a synchronized pace to pull a filament through asystem for straightening metallic filament at a predetermined rate; andutilizing at least one set of straightening rollers comprising at leasttwo rollers opposed to one another on opposite sides of the filamentfrom one another. The at least one set of straightening rollers isconfigured to straighten the filament prior to a subsequent operation onthe filament.

The method for straightening metallic filament can further include:placing the first pulling roller prior to the at least one set ofstraightening rollers and placing the second pulling roller subsequentto the at least one set of straightening rollers.

The method for straightening metallic filament can further include:straightening the filament in line with a drawing operation.Alternatively, the method for straightening metallic filament furtherinclude: straightening the filament offline during an operation separatefrom a drawing process.

The method provides that the at least one set of straightening rollerscan include a first set of straightening rollers and a second set ofstraightening rollers. Alternatively, the method provides that the atleast one set of straightening rollers can include a first set ofstraightening rollers, a second set of straightening rollers, and athird set of straightening rollers. There is no theoretical limit to thenumber of sets of straightening rollers utilized in this method.

The method for straightening metallic filament can further include:configuring the first pulling roller and the second pulling roller tocreate a tension in the filament. The method for straightening metallicfilament can further include: controlling the tension in the filament tobe a low value while using the at least one set of straightening rollersto relive a residual stress on the filament that causes the filament tobend.

The method provides that a diameter of each of the first pulling rollerand the second pulling roller is much larger than a diameter of thefilament. The method also provides that a diameter of the at least oneset of straightening rollers is much smaller than the size of thepulling rollers and much closer to a size of the filament.

The method for straightening metallic filament can further include:utilizing a tension measuring device configured to measure a tension onthe filament pulled through the system for straightening metallicfilament. The tension measuring device sends a signal to thesynchronized pulling rollers to maintain a very low tension on thefilament. If the tension becomes too high, the wire will not bestraightened.

There has thus been outlined, rather broadly, the more importantfeatures of the technology in order that the detailed descriptionthereof that follows may be better understood, and in order that thepresent contribution to the art may be better appreciated. There areadditional features of the technology that will be described hereinafterand which will form the subject matter of the claims appended hereto. Inthis respect, before explaining at least one embodiment of thetechnology in detail, it is to be understood that the invention is notlimited in its application to the details of construction and to thearrangements of the components set forth in the following description orillustrated in the drawings. The technology described herein is capableof other embodiments and of being practiced and carried out in variousways. Also, it is to be understood that the phraseology and terminologyemployed herein are for the purpose of description and should not beregarded as limiting.

As such, those skilled in the art will appreciate that the conception,upon which this disclosure is based, may readily be utilized as a basisfor the designing of other structures, methods and systems for carryingout the several purposes of the present invention. It is important,therefore, that the claims be regarded as including such equivalentconstructions insofar as they do not depart from the spirit and scope ofthe technology described herein.

Further objects and advantages of the technology described herein willbe apparent from the following detailed description of a presentlypreferred embodiment which is illustrated schematically in theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The technology described herein is illustrated with reference to thevarious drawings, in which like reference numbers denote like devicecomponents and/or method steps, respectively, and in which:

FIG. 1 is a side view schematic diagram of a system to straightenmetallic filament, according to an embodiment of the technology;

FIG. 2 is a side view schematic diagram of a system to straightenmetallic filament, according to an embodiment of the technology;

FIG. 3 is a side view schematic diagram of multiple sets of straightenstraightening rollers to straighten metallic filament, according to anembodiment of the technology;

FIG. 4 is an end view schematic diagram of multiple sets of straightenstraightening rollers to straighten metallic filament, according to anembodiment of the technology; and

FIG. 5 is a flowchart depicting a method for straightening metallicfilament.

DETAILED DESCRIPTION OF THE INVENTION

Before describing the disclosed embodiments of this technology indetail, it is to be understood that the technology is not limited in itsapplication to the details of the particular arrangement shown heresince the technology described is capable of other embodiments. Also,the terminology used herein is for the purpose of description and not oflimitation.

In various exemplary embodiments, the technology described hereinprovides systems and methods for drawn wire, commonly called filament,to be straightened after wet, cold, warm or hot drawing to a smallerdiameter. This technology controls tension on the wire after drawing,while pulling the wire through straightening rollers. A single set ofstraightening rollers can be used. There is no limit on the total numberof sets of straightening rollers can be used. The number of individualrollers in a set of straightening rollers can range from two-to-manyrolls. Tension is generally controlled by at least two relatively largediameter synchronizing sets of pulling rollers, one before thestraightening rollers and one after the straightening rollers as well asa device to measure and control tension. The filament tension must bevery low during straightening. The tension measuring device (a straingauge, for example) is used to send a signal to the synchronized pullcapstans to maintain the low tension by changing the speed of one pullroller.

Referring now to the Figures, a system 10 for straightening metallicfilament 16 is shown. The filament 16 can be straightened in line with adrawing operation. Alternatively, the filament 16 can be straightenedoffline during an operation separate from a drawing process.

The system 10 includes a first pulling roller 12 and a second pullingroller 14. The first pulling roller 12 and the second pulling roller 14are synchronized to rotate at a synchronized pace to pull a filament 16through the system 10 at a predetermined rate. The diameter of each ofthe first pulling roller 12 and the second pulling roller 14 is muchlarger than a diameter of the filament 16.

In at least one embodiment, the first pulling roller 12 is located priorto the at least one set of straightening rollers 20, 30, 40, and thesecond pulling roller 14 is located subsequent to the at least one setof straightening rollers 20, 30, 40. This order can be varied. The firstpulling roller 12 and the second pulling roller 14 rotate in directionof arrows 50 to pull the filament 16 through the system 10.

The system 10 includes at least one set of straightening rollerscomprising at least two rollers opposed to one another on opposite sidesof the filament from one another. As depicted in the Figures, the system10 can include a first set of straightening rollers 20, a second set ofstraightening rollers 30, and a third set of straightening rollers 40.There is no theoretical limit to the number of sets of straighteningrollers utilized in the system 10. Additionally, as few as one set ofstraightening rollers can be used to straighten filament 16.

Each set of straightening rollers 20, 30, 40 includes at least tworollers opposed to one another on opposite sides of the filament fromone another. By way of example, the first set of straightening rollers20 includes roller block assembly 22, 24 have at least one roller 26opposed by at least roller on an opposite side 28. The second set ofstraightening rollers 30 includes roller block assembly 32, 34 have atleast one roller 36 opposed by at least roller on an opposite side 38.The third set of straightening rollers 40 includes roller block assembly42, 44 have at least one roller 46 opposed by at least roller on anopposite side 48. The number of roller pairs (such as 26, 28) per eachset of straightening rollers 20, 30, 40 can vary. In most cases severalsets of straightening rollers containing, for example, 12 or moreindividual rollers should be used.

Each set of straightening rollers 20, 30, 40 can operate at variedangles relative to one another. By way of example (as best depicted inFIGS. 3 and 4), rollers 26 and 28 are opposed to one another andpressing against the filament 16 at generally 0 and 360 degrees. Rollers36 and 38 are opposed to one another and pressing against the filament16 at generally 45 and 225 degrees. Rollers 48 and 46 are opposed to oneanother and pressing against the filament 16 at generally 135 and 315degrees. These angles can be varied.

Nearly any amount of ring and cast can be straightened. Wire can bestraightened by controlling the wire tension to a constant low value andrunning wire through several sets of straightening rolls 20, 30, 40. Asdepicted in the Figures the several sets of straightening rolls 20, 30,40 are utilized on three planes.

The diameter of each roller 26, 28, 36, 38, 46, 48 of each set ofstraightening rollers, 20, 30, 40, while it can vary amongst rollers andsets of rollers, is much smaller than the size of the pulling rollersand much closer to a size of the filament 16. Each set of straighteningrollers is configured to straighten the filament 16 prior to asubsequent operation on the filament 16.

The first pulling roller 12 and the second pulling roller 14 areconfigured to create a tension in the filament 16. The tension iscontrolled to be a low value while using the set of straighteningrollers 20, 30, 40 to relive a residual stress on the filament 16 thatcauses the filament 16 to bend. The system 10 can include a tensionmeasuring device 18. The tension measuring device 18 is configured tomeasure a tension on the filament 16 pulled through the system 16 forstraightening metallic filament. The tension measuring device sends asignal to the synchronized pulling rollers to maintain a very lowtension on the filament. If the tension becomes too high, the wire willnot be straightened.

In operation, the method to straighten metallic filament after drawingutilizes a pulling roller to help remove filament from a wire carrier,spool, drawing machine or other machine to eliminating variations intension due to the wire carrier, spool, drawing machine or othermachine. The wire then travels through at least one set of twostraightening rollers slightly bending the filament to reduce oreliminate residual bending in the filament. In most cases several setsof straightening rollers containing for example 12 or more individualrollers should be used. Prior to winding, rewinding or otherwisecollecting the filament the wire passes through or over a tensionmonitoring devise and exits the straightening unit via a second pullingroller the function of which is to pull wire through the straighteningrollers at low tension. In this description, the tensioning monitoringdevice creates an electronic tension signal that synchronizes the twopulling rollers to ensure a constant low tension during straightening.

The systems and methods of this technology can be utilized on filamentsof varying diameters and at various line speeds. By way of example, inone exemplary embodiment, the system is utilized on small diameterfilaments that are less than 0.35 mm in diameter and straightened at arate of 15 meters per second.

As depicted in FIG. 5, the method for straightening metallic filamentcan include the following methods steps: drawing wire filament 502 (inwire direction 518), utilizing a first synchronized pulling roller 504,controlling tension in the filament 506, utilizing a first set ofstraightening rollers 508, utilizing a second set of straighteningrollers 510, utilizing a third set of straightening rollers 512,utilizing an N^(th) set of straightening rollers 514, and utilizing asecond synchronized pulling roller 516. The method steps and the orderin which the method steps are taken can be varied.

In one exemplaray embodiment, the method can be carried out by thefollowing steps: utilizing a first pulling roller; utilizing a secondpulling roller; synchronizing the first pulling roller and the secondpulling roller to rotate at a synchronized pace to pull a filamentthrough a system for straightening metallic filament at a predeterminedrate; and utilizing at least one set of straightening rollers comprisingat least two rollers opposed to one another on opposite sides of thefilament from one another. The at least one set of straightening rollersis configured to straighten the filament prior to a subsequent operationon the filament.

The method for straightening metallic filament can further include:placing the first pulling roller prior to the at least one set ofstraightening rollers and placing the second pulling roller subsequentto the at least one set of straightening rollers.

The method for straightening metallic filament can further include:straightening the filament in line with a drawing operation.Alternatively, the method for straightening metallic filament furtherinclude: straightening the filament offline during an operation separatefrom a drawing process.

The method provides that the at least one set of straightening rollerscan include a first set of straightening rollers and a second set ofstraightening rollers. Alternatively, the method provides that the atleast one set of straightening rollers can include a first set ofstraightening rollers, a second set of straightening rollers, and athird set of straightening rollers. There is no theoretical limit to thenumber of sets of straightening rollers utilized in this method.

The method for straightening metallic filament can further include:configuring the first pulling roller and the second pulling roller tocreate a tension in the filament. The method for straightening metallicfilament can further include: controlling the tension in the filament tobe a low value while using the at least one set of straightening rollersto relive a residual stress on the filament that causes the filament tobend.

The method provides that a diameter of each of the first pulling rollerand the second pulling roller is much larger than a diameter of thefilament. The method also provides that a diameter of the at least oneset of straightening rollers is much smaller than the size of thepulling rollers and much closer to a size of the filament.

The method for straightening metallic filament can further include:utilizing a tension measuring device configured to measure a tension onthe filament pulled through the system for straightening metallicfilament. The tension measuring device sends a signal to thesynchronized pulling rollers to maintain a very low tension on thefilament. If the tension becomes too high, the wire will not bestraightened.

Although this technology has been illustrated and described herein withreference to preferred embodiments and specific examples thereof, itwill be readily apparent to those of ordinary skill in the art thatother embodiments and examples can perform similar functions and/orachieve like results. All such equivalent embodiments and examples arewithin the spirit and scope of the disclosed technology and are intendedto be covered by the following claims.

1. A system for straightening metallic filament, the system comprising:a first pulling roller; a second pulling roller, the first pullingroller and the second pulling roller being synchronized to rotate at asynchronized pace to pull a filament through the system at apredetermined rate; and at least one set of straightening rollerscomprising at least two rollers opposed to one another on opposite sidesof the filament from one another; wherein the at least one set ofstraightening rollers is configured to straighten the filament prior toa subsequent operation on the filament.
 2. The system for straighteningmetallic filament of claim 1, wherein the first pulling roller islocated prior to the at least one set of straightening rollers and thesecond pulling roller is located subsequent to the at least one set ofstraightening rollers.
 3. The system for straightening metallic filamentof claim 1, wherein the filament is straightened in line with a drawingoperation.
 4. The system for straightening metallic filament of claim 1,wherein the filament is straightened offline during an operationseparate from a drawing process.
 5. The system for straighteningmetallic filament of claim 1, wherein the at least one set ofstraightening rollers is comprised of a first set of straighteningrollers and a second set of straightening rollers.
 6. The system forstraightening metallic filament of claim 1, wherein the at least one setof straightening rollers is comprised of a first set of straighteningrollers, a second set of straightening rollers, and a third set ofstraightening rollers.
 7. The system for straightening metallic filamentof claim 1, wherein the first pulling roller and the second pullingroller are configured to create a tension in the filament.
 8. The systemfor straightening metallic filament of claim 7, wherein the tension iscontrolled to be a low value while using the at least one set ofstraightening rollers to relive a residual stress on the filament thatcauses the filament to bend.
 9. The system for straightening metallicfilament of claim 1, wherein a diameter of each of the first pullingroller and the second pulling roller is much larger than a diameter ofthe filament, and wherein a diameter of the at least one set ofstraightening rollers is much smaller than the size of the pullingrollers and much closer to a size of the filament.
 10. The system forstraightening metallic filament of claim 1, further comprising: atension measuring device configured to measure a tension on the filamentpulled through the system for straightening metallic filament.
 11. Amethod for straightening metallic filament, the method comprising:utilizing a first pulling roller; utilizing a second pulling roller;synchronizing the first pulling roller and the second pulling roller torotate at a synchronized pace to pull a filament through a system forstraightening metallic filament at a predetermined rate; and utilizingat least one set of straightening rollers comprising at least tworollers opposed to one another on opposite sides of the filament fromone another; wherein the at least one set of straightening rollers isconfigured to straighten the filament prior to a subsequent operation onthe filament.
 12. The method for straightening metallic filament ofclaim 11, further comprising: placing the first pulling roller prior tothe at least one set of straightening rollers; and placing the secondpulling roller subsequent to the at least one set of straighteningrollers.
 13. The method for straightening metallic filament of claim 11,further comprising: straightening the filament in line with a drawingoperation.
 14. The method for straightening metallic filament of claim11, further comprising: straightening the filament offline during anoperation separate from a drawing process.
 15. The method forstraightening metallic filament of claim 11, wherein the at least oneset of straightening rollers is comprised of a first set ofstraightening rollers and a second set of straightening rollers.
 16. Themethod for straightening metallic filament of claim 11, wherein the atleast one set of straightening rollers is comprised of a first set ofstraightening rollers, a second set of straightening rollers, and athird set of straightening rollers.
 17. The method for straighteningmetallic filament of claim 11, further comprising: configuring the firstpulling roller and the second pulling roller to create a tension in thefilament.
 18. The method for straightening metallic filament of claim11, further comprising: controlling the tension in the filament to be alow value while using the at least one set of straightening rollers torelive a residual stress on the filament that causes the filament tobend.
 19. The method for straightening metallic filament of claim 11,wherein a diameter of each of the first pulling roller and the secondpulling roller is much larger than a diameter of the filament, andwherein a diameter of the at least one set of straightening rollers ismuch smaller than the size of the pulling rollers and much closer to asize of the filament.
 20. The method for straightening metallic filamentof claim 11, further comprising: utilizing a tension measuring deviceconfigured to measure a tension on the filament pulled through thesystem for straightening metallic filament.